Care and Safety - includes warnings and cautions
pertinent to aspects of workshop procedures etc.

3

Maintenance - includes service schedules and
recommended lubricants for all the machine.

T11-004

This publication is designed for the benefit of JCB
Distributor Service Engineers who are receiving, or have
received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and general
techniques associated with the maintenance and repair of
hydraulic earthmoving equipment.
The illustrations in this publication are for guidance only.
Where the machines differ, the text and/or the illustration
will specify.
General warnings in Section 2 are repeated throughout the
manual, as well as specific warnings. Read all safety
statements regularly, so you do not forget them.
Renewal of oil seals, gaskets, etc., and any component
showing obvious signs of wear or damage is expected as
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid and ingress of dirt.

The remaining sections are alphabetically coded and deal
with Dismantling, Overhaul etc. of specific components, for
example:
A

In this publication, the S.I. system of units is used. For
example, liquid capacities are given in litres. The Imperial
units follow in parentheses ( ) eg 28 litres (6 gal).

Where a torque setting is given as a single figure it may be
varied by plus or minus 3%. Torque figures indicated are
for dry threads, hence for lubricated threads may be
reduced by one third.
The manufacturer's policy is one of continuous
improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will
be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
contained in this publication.
Finally, please remember above all else safety must come
first!

Section Numbering
T11-005

The manual is compiled in sections, the first three are
numbered and contain information as follows:

1-1

9803/9400-08

1-1

Section 1 - General Information
Introduction
About this Publication

Left Side, Right Side
P2-1002

In this manual, 'left' A and 'right' B mean your left and right
when you are seated correctly in the machine.
This is so whether you are facing the loader (front) or the
backhoe (rear).

A

B

A

B
C003690

Fig 1.

Cab/Canopy
T1-003_2

This manual frequently makes references to the cab. For
instance, 'do not operate the machine without a manual in
the cab'. It should be noted that these statements also
apply to canopy build machines.

Cross References
T1-004_2

In this publication, page cross references are made by
presenting the subject title printed in bold, italic and
underlined. It is preceeded by the 'go to' symbol. The
number of the page upon which the subject begins, is
indicated within the brackets. For example: K Cross
References ( T 1-2).

1-2

9803/9400-08

1-2

Section 1 - General Information
Introduction
Identifying the Machine

Identifying the Machine
Machine Identification Plate
The machine has an identification plate mounted on the
loader tower. The serial numbers of the machine and its
major units are stamped on the plate.
The serial number of each major unit is also stamped on
the unit itself. If a major unit is replaced by a new one, the
serial number on the identification plate will be wrong.
Either stamp the new number of the unit on the
identification plate, or simply stamp out the old number.
This will prevent the wrong unit number being quoted when
replacement parts are ordered.
The machine and engine serial numbers can help identify
exactly the type of equipment you have.

Typical Vehicle Identification Number (VIN)
T025210-1

Fig 2.
SLP

Midi

T

S

6

E

972021

1

2

3

4

5

6

7

Typical Product Identification Number (PIN)
P2-1006

1

World Manufacturer Identification (SLP = JCB)

2

Machine Model

3

Steer Type (T= 2WS, F= 4WS)

4

Build Type (S=Sideshift, C=Centremount, L=Loader)

1

World Manufacturer Identification (3 Digits)

5

Year of Manufacture:

2

Machine Model (5 Digits)

6 = 2006

3

Check Letter (1 Digit)

T016220-8

Fig 3.

7 = 2007

The Check Letter is used to verify the authenticity of
a machine's PIN.

Do not use the machine if the falling objects protection
level provided by the structure is not sufficient for the
application. Falling objects can cause serious injury.
8-2-8-17

If the machine is used in any application where there is a
risk of falling objects then a falling-objects protective
structure (FOPS) must be installed. For further information
contact your JCB Dealer
The falling objects protection structure (FOPS) is fitted with
a dataplate. The dataplate indicates what level protection
the structure provides.
There are two levels of FOPS:

Obey
the
usual
routine
maintenance
schedules
and
Important: Engines operated with procedures. Fuel additives are
these fuels may have a reduced recommended for use with low
service life.
sulphur
fuels(1).
K Additives ( T 1-9).

tank (or the storage tank). Water will encourage micobacterial growth.

The additives listed below are advertised as being suitable
for bringing the lubricity levels of kerosene/low sulphur
fuels up to those of diesel fuels. They must be used as
specified by your fuel supplier who will understand the
concentration level necessary.

– Make sure that the fuel pre-filter is drained daily (not
every week as currently advised).
– Only Tier 3 engines (factory filled with CH4 oil) - this
is not approved with other manufacturers.
– Use heater kits in low ambient temperature territories.

Important: The lubricity wear scar diameter must not be
more than 460 microns, as tested on a high frequency
reciprocating rig at 60°C (140°F). Refer to ISO 12156-1.
– Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%),
specifically for Indian Superior Kerosene (SKO) but
may be applicable to other fuels.
– Lubrizol 539N. Dosage (on Swedish low sulphur fuel)
250 ppm.
– Paradyne 7505 (from Infineum). Dosage 500 ppm
(0.05%).
Note: These products are given as examples only. The
information is derived from the manufacturers data. The
products are not recommended or endorsed by JCB.
Service Requirements for use of B5 Biodiesel
– The engine oil must be a grade CH4 as minimum
specification.
– Do not leave unused B5 biodiesel in the fuel tank for
extended periods (top up each day).

– The biodiesel must meet the following standards:
ASTM D6751, DIN 51606, ISO 14214
Note: If necessary use a test kit to confirm the fuel
specification. Testing kits are available (not from JCB
currently), use the internet as a source for the kits.
Note: If performance related issues are to be reported to
JCB Service, and the engine has been run on biodiesel,
then the fuel system must be filled with standard diesel (at
least 2 x tank fills) to EN590 specification and relevant stall
speeds recorded prior to making the report.
Warranty
JCB have shown a commitment to support the
environment by approving the use of biodiesel blended
fuels.
Using a B5 blend of biodiesel requires caution and
additional servicing of the engine is required. K Service
Requirements for use of B5 Biodiesel ( T 1-9).

– Make sure that 1 in 5 fuel tank fills use standard diesel
to EN590 specification, this will help to prevent
'gumming'.

Failure to follow the additional recommended service
requirements may lead to a warranty claim being declined.

Failures resulting by the incorrect use of biodiesels or
other fuel additives are not defects of the engine
workmanship and therefore will not be supported by JCB
Warranty.

– Change the engine oil and filter more frequently (as a
minimum half the recommended intervals), or as
indicated by oil sampling.
– Change the fuel filters more frequently (as a minimum
half the recommended intervals), or if there are
engine performance related issues.
– Make sure the fuel is stored correctly, care must be
taken to make sure no water enters the machine fuel

1-9

9803/9400-08

1-9

Section 1 - General Information
Introduction
Fuel
Sulphur Content

Effects of Fuel Contaminates
T3-032

T3-033

High sulphur content can cause engine wear. (High
sulphur fuel is not normally found in North America,
Europe or Australia.) If you have to use high sulphur fuel
you must change the engine oil more frequently.
K Table 2. Sulphur Content ( T 1-10).

The effect of dirt, water and other contaminants in diesel
can be disastrous for injection equipment:

!MCAUTION
A combination of water and sulphur will have a
corrosive chemical effect on fuel injection equipment.
It is essential that water is eradicated from the fuel
system when high sulphur fuels are used.
ENG-3-2

– Dirt - A severely damaging contaminant. Finely
machined and mated surfaces such as delivery
valves and distributor rotors are susceptible to the
abrasive nature of dirt particles - increased wear will
almost inevitably lead to greater leakage, uneven
running and poor fuel delivery.
– Water - Water can enter fuel through poor storage or
careless handling, and will almost inevitably
condense in fuel tanks. The smallest amounts of
water can result in effects that are just as disastrous
to the fuel injection pump as dirt, causing rapid wear,
corrosion and in severe cases, even seizure. It is
vitally important that water is prevented from reaching
the fuel injection equipment. The filter/water trap must
be drained regularly.
– Wax - Wax is precipitated from diesel when the
ambient temperature falls below that of the fuel's
cloud point, causing a restriction in fuel flow resulting
in rough engine running. Special winter fuels may be
available for engine operation at temperatures below
0°C (32°F). These fuels have a lower viscosity and
limit wax formation.

Some external fasteners on JCB machines are
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet and
replaces the original Zinc and Yellow Plating used on
earlier machines.

Use the following torque setting tables only where no
torque setting is specified in the text.

The two types of fasteners can be readily identified by
colour and part number suffix. K Table 3. Fastener Types
( T 1-10).

Torque settings are given for the following conditions:

Fastener
Type

Table 3. Fastener Types
Colour
Part No. Suffix

Note: Dacromet fasteners are lubricated as part of the
plating process, do not lubricate.

Note: As the Dacromet fasteners have a lower torque
setting than the Zinc and Yellow fasteners, the torque
figures used must be relevant to the type of fastener.
Note: A Dacromet bolt should not be used in conjunction
with a Zinc or Yellow plated nut, as this could change the
torque characteristics of the torque setting further. For the
same reason, a Dacromet nut should not be used with a
Zinc or Yellow plated bolt.

– Lubricated zinc and yellow plated fasteners
– Where there is a natural lubrication. For example,
cast iron components

Verbus Ripp Bolts

Note: All bolts used on JCB machines are high tensile and
must not be replaced by bolts of a lesser tensile
specification.
Note: Dacromet bolts, due to their high corrosion
resistance are used in areas where rust could occur.
Dacromet bolts are only used for external applications.
They are not used in applications such as gearbox or
engine joint seams or internal applications.

1-10

Fig 8.
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.

Fig 10.
`Torque Stop' Hoses 10-B screwed into adaptors 10-A seal
onto an 'O' ring 10-C which is compressed into a 45Â° seat
machined in the face of the adaptor port. To prevent the 'O'
ring being damages as a result of over tightening, 'Torque

Service Tools
Numerical List
The tools listed in the table are special tools required for
carrying out the procedures described in this manual.
These tools are available from JCB Service.
Some tools are available as kits or sets, the part numbers
for parts within such kits or sets are not listed here. For full

Part
Number

details of all tools, including the content of kits and sets,
see the relevant section in this manual.
Note: Tools other than those listed will be required. It is
expected that such general tools will be available in any
well equipped workshop or be available locally from any
good tool supplier.